Apparatus for producing crimped fibers



0ct. 3, 1967 JQlCHl KlTAJlM-A ET AL 3,344,472

APPARATUS FOR PRODUCING CRIMPED FIBERS [Filed Feb. 18, 1964 ll Sheets-Sheet 1 JolcHl KITAJIMA ETAL 3,344,472

APPARATUS FOR PRODUCING CRIMPED FIBERS Oct. 3,1967.

11 Sheets-Sheet 2 Filed Feb 18, 1964 o 1 7 JOICHI KITAJIMA E AL 3,344,472

APPARATUS FOR PRODUCING CRIMPED FIBERS Filed Feb. 18, 1964 11 Sheets-Sheet :3

EHSEIEIIEEIEIB [3515551315 Oct. 3, 1967 JOICHI KITAJIMA .ET AL 3,344,472 v APPARATUS,FOR PRODUCING CRIMPED FIBERS 7 v1 1 Sheets-Sheet 5 Filed Fb. 18, 1964- 1967 JOICHI KITAJIMA ETAL ,34

APPARATUS FOR PRODUC I NG OR I MPED F IBERS Filed Feb. 18, 1954 11 Sheets-Sheet e A I Oct- 1967' 401cm KITAJIMA L APPARATUS FOR PRODUCING GRIMPED FIBERS I Filed Feb. 18, 1964 11 She ets-Shee't 7 Fig. /3

Oct 3, 1967 JOICHI KITAJIMA ETAL 3,344,472

APPARATUS FOR PRODUCING CRIMPED FIBERS Filed Feb. 18, 1964 I 11 Shaets-Shet a Oct. 3 1-967 JOICHIV KITAJIMA ETAL Q 3,344,472

APPARATUS FOR PRODUCINGCRIMPED FIBERS Oct. 3, 1967 JOlCl-H KITAJIMA A 3,344,472

APPARATUS FOR PRODUCING CRIMPED FIBERS Filed Feb; 18, 1964 11 sheets-sheet 11 United States Patent O 3,344,472 APPARATUS FOR PRODUCING CRIMPED FIBERS Joichi Kitajima, Keishiro Ueno, and Haruo Sugimoto, Ohtake-shi, Japan, assignors to Mitsubishi Rayon C0., Ltd. and Mitsubishi Vonnel C0., Ltd., both of Tokyo, Japan, and both corporations of Japan Filed Feb. 18, 1964, Ser. No. 345,759 Claims priority, application Japan, Feb. 20, 1963, 38/8,900; Aug. 31, 1963, 38/463339; Oct. 12, 1963, 38/ 54,364

11 Claims. (Cl. 188) This invention relates to a spinning apparatus for producing novel composite fibers.

In the past much effort has been extended towards the production of artificial fibers having wool like appearance while retaining the various advantages of synthetic fibers.

As one method for producing these fibers, a conjugate spinning method has been recently proposed. The conjugate spinning method is an attempt to dispose at least two fiber forming materials having different shrinking properties eccentrically through the entire length of a filament by extruding simultaneously at least two different spinning solutions through each of a plurality of orifices into a coagulating medium. However the construction of a spinning apparatus used in this method is extremely complicated.

Accordingly it is one of the disadvantages of the conjugate spinning method that the number of orifices of spinneret cannot be readily increased. Moreover, it has been experienced that on account of the low dimensional stability of spun yarns and of knitting fabrics made from the fibers produced by the conjugate spinning method, handling of spun yarns, of knitting fabrics and of final products are extremely difficult.

An object of the present invention is to provide a composite spinning apparatus which overcomes these defects. In accordance with the present invention, three kinds of fibers, i.e. two kinds of fibers containing only single fiber f-ormingmaterial, and composite fibers containing two fiber forming materials eccentrically disposed can be spun. Each composite filament extruded from a spinning apparatus of the present invention is continuously different in proportion of each fiber forming material, by which shrinkage of each fiber extruded from the spinning apparatus of the present invention is also continuously different.

Accordingly, when spun yarns made from these fibers are subjected to shrinkage treatment, displacement of fibers in the spun yarn occurs and fibers having low shrinkage stand out of the yarns and contribute to impart-high bulk and excellent hand feel to the yarns. As filaments having high shrinkage are in a state of tension in the interior of the yarn, they contribute to maintain dimensional stability while suppressing excessive elongation at a small load.

The present invention is described more specifically with reference to accompanying drawings. FIG. 1 is an elevational view of a longitudinal cross section of an apparatus of the present invention. FIG. 2 is a plan view of a cross section taken along the line 11-11 of FIG. 1 and FIG. 7. FIG. 3 is an elevational view of a longitudinal cross section of another apparatus of the present invention. FIG. 4 is a plan view of a cross section taken along the line IV-IV of FIG. 3 and FIG. 8. FIG. 5 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 6 is a plan view of a cross section taken along the line VV of FIG. 5 and FIG. 9. FIG. 7 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 8 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 9 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 10 is a transversal cross section of spinning solution streams immediately after a distributor 3. FIG. 11 is a transversal cross section of spinning solution streams at the back of a spinneret 9, i.e. at the position just approaching a spinneret 9. FIG. 12 is an enlarged diagram of a part of FIG. 11 showing the relative position between the boundary of two spinning solution streams and orifices. FIG. 13 is an elevational View of a longitudinal cross section of still another apparatus of the present invention. FIG. 14 is a plan view of a cross-section taken along the line XIVX1V of FIG. 13. FIG. 15 is a plan view of a cross section taken along the line XVXV of FIG. 13 and FIG. 19. FIG. 16 is a plan view of a cross section taken along the line XVIXVI of FIG. 13. FIG. 17 is a transversal cross section of spinning solution streams immediately after the distributor 3 in the apparatus of FIGS. 13-16, 19, and 20. FIG. 18 is an enlarged diagram of a part of FIG. 17. FIG. 19 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 20 is a plan view of a cross section taken along the line XX-XX of FIG. 19. FIG. 21 is an elevational view of a longitudinal cross section of still another apparatus of the present invention. FIG. 22 is an elevational view of a longitudinal cross section of still another apparatus of the 7 present invention. FIG. 23 is a transversal cross section of spinning solution streams passing case 20 with filter material 21 of the apparatus of FIG. 22. FIG. 24 is a transversal cross section of spinning solution streams at the back of the spinneret 9 of the apparatus of FIG. 22 i.e. at the position just approaching the spinneret 9.

Referring to the drawings in FIGS. 1-6, 1 is a housing of a spinneret apparatus to which two kinds of spinning solutions are fed. 2 is a hollow conical sleeve inserted in the housing. 3 is the spinning solution distributor composed of two distributor plates. Plate 3-6 has a number of zigzag arranged projections 3-4 having small holes 3-5 perforated therethrough and plate 33 has the same number and same rarangement of small holes 3-2 as the small holes 3-5 of distributor plate 3-6. These two distributor plates are secured with a pin 4 in such a way that each of the small holes of distributor plate 33 and distributor plate 3-6 are in substantial alignment, the top surfaces of the projections 3-4 and the opposing surface of the distributor plate 3-3 forming a constricted zone 3-7. 3-8 is a spacer ring for the spinning solution distributor 3 having apertures 3-9 in its whole circumference which open into inner cavity 3-10 of the spinning solution distributor plate 3. Pin 4 also fixes the relative position between the hollow conical sleeve 2 and the spinning solution distributor 3. 5 and 7 are ring-shaped packings. 9 is a spinneret. 10 are orifices perforated through the spinneret 9, the number of which is greater than that of the small spinning solution holes of the distributor plate. 6 is a spacer which serves to place the distributor 3 at a suitable distance from the spinneret 9. 11 is a cap nut which secures distributor 3, the spacer 6 and the spinneret 9 to the housing of spinneret apparatus 1. 12 is a conduit for one spinning solution. 13 is a spinning solution reservoir formed by the hollow conical sleeve 2 and the spinning solution distributor 3. 14 is a conduit for a second spinning solution. 15 is a narrow passage for the second spinning solution formed between the conical inner wall of the housing of the spinneret apparatus 1 and the outer wall of the hollow conical sleeve 2. 16 is a reservoir for the second spinning solution. 17 is an annular passage for the other spinning solution formed between the cylindrical inner wall of the housing 1 and the outer circumference of the spinning solution distributor 3. 18 is a cavity formed between the spinning solution distributor 3 and the spinneret 9.

The first spinning solution is introduced through conduit 12 into the spinneret apparatus. After filling the reservoir 13, the first spinning solution flows uniformly through the small holes of the distributor plate 3-3, toward the orifices while passing the small holes 3-5 of the other distributor plate 3-6. On the other hand the second spinning solution is introduced through conduit 14, through the constricted passage to the reservoir 16. After filling this reservoir 16, the second spinning solution flows through the annular passage 17, through side holes 3-9 into the inner cavity 310. Because of the constricted zone 37, the second spinning solution is uniformly distributed and flows into the small holes 35 surrounding the streams of the first spinning solution coming from the small holes 32 of distributor plate 33, and the streams of spinning solution consisting of a core of the first spinning solution and a sheath of the second spinning solution are delivered toward the orifices 10 of the spinneret 9.

The spinning solution delivered from the small holes 35 takes the distinct shape of sheath and core as shown in FIG. 10 and flows into the cavity 18 while filling this cavity in the form shown in FIG. 11. In other words, the streams of the first spinning solution are surrounded by that of the second spinning solution with distinct boundaries, and are not mixed. The number of the streams of the first spinning solution are equal to that of the small holes of distributor plate 36.

As shown in FIG. 12, the orifices 10-1 are positioned on a boundary of the first and the second spinning solutions, and the solutions are extruded therethrough in composite form the orifices 10-2 are positioned such that the first spinning solution, one spinning solution alone is extruded, and the orfices 103 are positioned such that the second spinning solution alone is extruded therethrough.

The distributor 3 in FIG. 7 to FIG. 9 is different from that in FIG. 1 to FIG. 6. Both distributor plates 33 and 37 are provided with projections 31 and 34 respectively. Holes 32 and 35 are in substantial alignment and the top surfaces of projections 31 and 34 are directly opposed to form constricted zones 37.

In FIG. 13 to FIG. 16 distributor plate 3-3 is provided with elongated raised platforms 311 which extend completely across plate 33 and through which the small holes 32 are perforated. The other distributor plate 312 is planar and is provided the same number and the same arrangement of the small holes 35 as those of the small holes 3-2 and said two distributor plates are spaced in parallel to form constricted zone 37. The cross section of the spinning solution streams immediately after passing through the distributor takes the form as shown FIG. 17. The cross section of the spinning solution stream in the cavity 18 takes the form as shown in FIG. 11.

In FIGS. 19 and 20, the spinning solution distributor 3 is constructed with two distributor plates 33 which both have the same number of and the same arrangement of platforms 3-11.

In FIG. 21, a curved pipe 22 is installed between the above mentioned spinning solution distributor 3 and the spinneret 9. The flow of the spinning solution is the same as in the above-mentioned apparatus. It flows toward the spinneret 9 while filling the pipe.

In FIG. 22 a case 20 filled with a filter material 21 is inserted in the part corresponding to the cavity 18 and the spinning solution therein takes the cross section as shown in FIG. 23. When it reaches the orifices 10, it takes the shape as shown in FIG. 24.

Accordingly, the bundles of filaments extruded from the present apparatus comprise three kinds of filament, i.e. a so-called composite filament in which a first polymer constituent from one spinning solution is joined with a second polymer constituent from another spinning solution, a filament composed of only said first polymer constituent and a filament composed of only said second polymer constituent. In these filament bundles, the ratio of the composite filaments to non-composite filaments is determined by the ratio of total number of orifices (101) positioned on the border of streams of the different kinds of spinning solution 12 vs. total number of orifices (102) and (10-3) positioned off border of streams of the different kinds of spinning solution N, in a spinnert placed underneath the distributor. As the value n/N is greater, so is the amount of composite filament greater. From considerations of the required properties of filament bundles, restrictions enforced from the apparatus, and for reasons of economy and production, the value of n/N must be in the range 2085/8015.

That is to say, should n/N be less than 20/80, the number of composite filaments would be too small com pared to the number of non-composite filaments, and a potentially crimpable filament bundle, which is the object of the present invention, would not be obtained. On the other hand, should n/N be greater than 85/15, not only could potential crimpability, good length stability and good bulkiness could not be obtained, but additionally the apparatus would become complicated and would not be practicable due to poor productivity, spinning stability and investment cost. Thus, by selecting the n/N value within the range of 20-85/ 15, filament bundles having optionally desired stability and potential crimpability can be obtained.

The time of travel from the joining of the first spinning solution with the second in the spinning solution distributing holes 35 of the spinning solution distributor 3 to the back of the spinneret 9 is related to the difference of properties of two spinning solutions and their mutual solubility and accordingly it is not critical within a broad range, but is generally in the range of 5 to 30 seconds.

It is preferable that the distance between the spinning solution distributor 3 and the spinneret 9, be greater than 2.5 mm.

The diameter of the small spinning solution distributing holes 3-2 and 3-5 may be greater than the diameter of orifices 10, and the range covers 0.5 mm. to 5 mm.

In accordance with the present invention, it is possible to produce filament bundles wherein composite filaments and non-composite filaments are mixed simultaneously, unevenly and uniformly all over the entire surface of the spinneret 9. Accordingly, these filament bundles afford the effect of making the mixing step of two kinds of fibers in the spinning operation simpler. They also afford the further advantage that the ratio of composite filaments spun is greater than can be achieved by conventional apparatus of this kind. Due to the better shape-stability of spun yarns and knitted fabrics produced with these filament bundles, they afford another advantage in that the bundling of spun yarns, knitted fabrics and final products is simpler.

What we claim is:

1. A spinneret assembly comprising a first and second fluid supply means, a distributor common to said first and second fluid supply means and having a plurality of distribution orifices defined thereby, a spinneret spaced from said distributor and having a plurality of extrusion orifices defined thereby, a fluid carrying chamber defined by said distributor and spaced spinneret, means associated with said distributor for providing a flow of spaced filaments of said first fluid, each of said filaments being substantially encased in a flow of said second fluid to form borders between said fluids, the ratio of the number of extrusion orifices of said spinneret contacted by said fluid borders to the total number of extrusion orifices contacted by said first fluid alone and said second fluid alone being 20-85z80-15.

2. The spinnert assembly of claim 1 wherein said distributor comprises a first distributor plate having at least one projection therein and at least one distribution orifice defined by said projection and a second distributor plate having the same number and arrangement of orifices as said first distributor plate, said plates being arranged in parallel with the distribution orifices of each being in substantial alignment.

3. The spinneret assembly of claim 2 wherein said projection is an elongated raised platform extending completely across said first distributor plate.

4. The spinneret assembly of claim 1 wherein said distributor comprises a first distributor plate having at least one projection therein and at least one distribution orifice defined by said projection and a second distributor plate having the same number and arrangement of projections and orifices as said first distributor plate, said plates being arranged in parallel with the projections of each in close spaced relation and the distribution orifices of each in substantial alignment.

5. The spinneret assembly of claim 4 wherein said projections are elongated raised platforms extending com pletely across said plates.

6. The spinneret assembly of claim 1 wherein the fluid carrying chamber is in the form of an elongated pipe.

7. The spinneret assembly of claim 1 wherein said fluid carrying chamber is provided with a case filled with a filter material.

8. The spinneret assembly of claim 7 wherein said distributor comprises a first distributor plate having at least one projection therein and at least one distribution orifice defined by said projection and a second distributor plate having the same number and arrangement of orifices as said first distributor plate, said plates being arranged in parallel with the distribution orifices of each being in substantial alignment.

9. The spinneret assembly of claim 8 wherein said projection is an elongated raised platform extending completely across said first distributor plate.

10. The spinneret assembly of claim 7 wherein said distributor comprises a first distributor plate having at least one projection therein and at least one distribution orifice defined by said projection and a second distributor plate having the same number and arrangement of projections and orifices as said first distributor plate, said plates being arranged in parallel with the projections of each in close spaced relation and the distribution orifices of each in substantial alignment.

11. The spinneret assembly of claim 7 wherein said projections are elongated raised platforms extending completely across said plates.

References Cited UNITED STATES PATENTS 823,009 6/1906 Waddell 18-8 858,648 7/ 1907 Ernst 18-8 2,386,173 10/1945 Kulp et al 18-8 2,428,046 9/1947 Sisson et al. 18-8 XR 2,589,870 3/1952 Sale et al 18-8 2,843,875 7/ 1958 Albohn et al 18-8 3,017,686 1/1962 Breen et a1. 18-8 XR 3,188,689 6/1965 Breen 18-8 WILLIAM J. STEPHENSON, Primary Examiner. 

1. A SPINNERET ASSEMBLY COMPRISING A FIRST AND SECOND FLUID SUPPLY MEANS, A DISTRIBUTOR COMMON TO SAID FIRST AND SECOND FLUID SUPPLY MEANS AHD AHVING A PLURALITY OF DISTRIBUTION ORIFICES DEFINED THEREBY, A SPINNERET SPACED FROM SAID DISTRIBUTOR AND HAVING A PLURALITY OF EXTRUSION ORIFICES DEFINED THEREBY, A FLUID CARRYING CHAMBER DEFINED BY SAID DISTRIBUTOR AND SPACED SPINNERET, MEANS ASSOCIATED WITH SAID DISTRIBUTOR FOR PROVIDING A FLOW OF SPACED FILAMENTS OF SAID FIRST FLUID, EACH OF SAID FILAMENTS BEING SUBSTANTIALLY ENCASED IN A FLOW OF SAID SECOND FLUID TO FORM BORDERS BETWEEN SAID FLUIDS, THE RATION OF THE NUMBER OF EXTRUSION ORIFICES OF SAID SPINNERET CONTACTED BY SAID FLUID BORDERS TO THE TOTAL NUMBER OF EXTRUSION ORIFICES CONTACTED BY SAID FIRST FLUID ALONE AND SAID SECOND FLUID ALONE BEING 20-85:80-15. 